Low-Sodium Salt Granulation via Dry Compaction
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Solution Overview
Problem
Existing processes for producing low sodium salt products often result in heterogeneous mixtures due to particle size differences between sodium chloride and additives, leading to demixing during transport and storage, and require water addition and removal steps, making them inefficient and vulnerable to attrition.
Innovation Solution
A process involving crushing sodium chloride and additive materials to specific size ranges, followed by compacting under dry conditions using pressure, and subsequent crushing to achieve a homogeneous low sodium salt product with improved taste and segregation resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If additives with smaller particle size than sodium chloride are mixed with sodium chloride, then the additive can be effectively incorporated into the salt product, but demixing occurs upon transport and storage due to particle size differences
Solution Approach 1:
The patent applies the nesting principle by incorporating smaller additive particles inside larger salt particles through a two-stage process: first mixing fine additives with fine salt particles, then granulating with coarser salt particles. This creates a nested structure where additives are trapped inside the salt particle matrix, preventing demixing during transport and storage while maintaining homogeneous distribution.
Solution Approach 2:
The patent changes the particle size parameter systematically by using different particle size ranges for different components at different stages: fine particles (0-63 microns) for additives and fine salt in the first mixing stage, and coarser particles (63-250 microns) for granulation in the second stage. This parameter change ensures proper incorporation while maintaining stability.
2Stability of the object's composition
If a wet granulation process with water addition is used to produce salt particles, then additives can be incorporated into the salt product, but the process becomes inefficient and produces particles vulnerable to attrition
Solution Approach 1:
The patent extracts the water step from the traditional wet granulation process, creating a dry granulation method. By removing water as a binding agent and relying instead on mechanical compaction and particle size distribution, the process eliminates the need for water addition and subsequent drying steps, significantly improving efficiency while producing more attrition-resistant particles.
Solution Approach 2:
The patent replaces the chemical/wet binding mechanism (water-based granulation) with a mechanical binding mechanism (dry compaction and particle size-based granulation). This substitution eliminates the inefficiencies of water addition, mixing, and drying steps while producing particles with better mechanical strength and lower attrition.
3Stability of the object's composition
If additives are located on the outer surface of salt particles, then the additive distribution appears homogeneous, but the salt product shows increased hygroscopic behavior
Solution Approach 1:
The patent uses nesting to place additive particles inside the salt particle structure rather than on the outer surface. The fine additives are incorporated into the fine salt matrix first, then this mixture is granulated with coarser salt particles, creating a nested structure where additives are entrapped inside. This prevents direct exposure to moisture while maintaining homogeneous distribution throughout the product.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process results in a homogeneous low sodium salt product with enhanced taste and improved attrition resistance, where additives are evenly distributed within the salt particles, reducing the risk of demixing and maintaining product integrity during handling and storage.
Implementation Method 1
compacting the particle mixture resulting from step c.) using a pressure of from 40 to 400 MPa
Implementation Method 2
crushing the compacted salt product to give particles of the desired particle size
Data Source
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AI summary
The present invention relates to a process to prepare a salt product containing sodium chloride (NaCI) and at least one additive, wherein the salt product has a particle size of from 50 μm to 10 mm, which process comprises the steps of: a) optionally, crushing a sodium chloride-containing material to a particle size that is between 1,000 times smaller and 3 times smaller than the size of the final salt product; b) optionally, crushing the at least one additive starting material to a particle size that is between 0.5 and 2 times the particle size of the sodium chloride-containing material particles resulting from step a.); c) subsequently, mixing the sodium chloride-containing material particles of a particle size that is between 1,000 times smaller and 3 times smaller than the size of the final salt product, and additive particles of a particle size that is between 0.5 and 2.0 times the particle size of the sodium chloride-containing material particles; d) subsequently, compacting the particle mixture resulting from step c.) using a pressure of from 40 to 400 MPa; e. subsequently, crushing the compacted salt product to give particles of the desired particle size of 50 μm to 10 mm; wherein the steps are carried out under substantially dry conditions. Additionally, the invention provides the low sodium salt product obtainable by the process and the use thereof for human or animal consumption.